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Biomass Wood Fired Water Heaters

Installation, Maintenance and

Technical Instructions

Firex 34 - 55kW

2

General information

TABLE OF CONTENTS

1 GENERAL INFORMATION .................................................................................................................................................................................3 1.1 Symbols used in the manual .......................................................................................................................................................................3 1.2 Appropriate use of appliance ......................................................................................................................................................................3 1.3 Water treatment ...........................................................................................................................................................................................3 1.4 Information for user or system manager ....................................................................................................................................................3 1.5 Safety warnings ...........................................................................................................................................................................................4 1.6 Technical data plate.....................................................................................................................................................................................4 1.7 General warnings .........................................................................................................................................................................................5

2 TECHNICAL FEATURES AND DIMENSIONS ...................................................................................................................................................6 2.1 Technical features ........................................................................................................................................................................................6 2.2 Hydraulic dimensions and connections .....................................................................................................................................................6

2.3 Technical data ..............................................................................................................................................................................................7 2.4 Main components ........................................................................................................................................................................................8 2.5 General .........................................................................................................................................................................................................8 3 INSTRUCTIONS FOR THE INSTALLATION TECHNICIAN .............................................................................................................................11 3.1 General warnings .....................................................................................................................................................................................11 3.2 Installation standards ...............................................................................................................................................................................11

3.3 Packaging .................................................................................................................................................................................................12 3.4 Trasport .....................................................................................................................................................................................................12 3.5 Positioning in boiler room .......................................................................................................................................................................13 3.6 Connecting boiler to system ....................................................................................................................................................................13 3.7 Flue connection ........................................................................................................................................................................................14 3.8 Connecting to safety heat exchanger drain ............................................................................................................................................15

3.9 Recirculation pump ..................................................................................................................................................................................16 3.10 Assembly instructions ..............................................................................................................................................................................16

3.11 Electrical connections ..............................................................................................................................................................................19 3.12 Optional panel board ................................................................................................................................................................................20 3.13 Diagrams of hydraulic and electrical connections ..................................................................................................................................22 3.14 Filling the system ......................................................................................................................................................................................23

4 BOILER START-UP ...........................................................................................................................................................................................24 4.1 Commissioning ........................................................................................................................................................................................ 24 4.2 The wood ..................................................................................................................................................................................................25 4.3 Wood humidity .........................................................................................................................................................................................25 4.4 Dimensions ...............................................................................................................................................................................................25 4.5 Controls upon commissioning .................................................................................................................................................................25 4.6 Start-up .....................................................................................................................................................................................................26 4.7 Combustion air adjustment ......................................................................................................................................................................27

4.8 Controls that must be carried out after the first start-up .......................................................................................................................27 4.9 Warnings ...................................................................................................................................................................................................28

4.10 Thermostat adjustment ............................................................................................................................................................................28 4.11 Summer mode ..........................................................................................................................................................................................29 4.12 Troubleshooting ........................................................................................................................................................................................29

5 INSPECTION AND MAINTENANCE ................................................................................................................................................................30

3

General information

1.1 - SYMBOLS USED IN THE MANUAL

Pay special attention when reading this manual to the parts marked by the symbols:

NOTE!Suggestions for the user

ATTENTION!Possible hazardous situation for the product and the environment

DANGER!Serious danger for personal safety and life

1.2 - APPROPRIATE USE OF APPLIANCE

The FIREX appliance has been built according to the current level of engineering and acknowledged technical safety rules. Nonetheless, if improperly used, dangers could arise for the safety and life of the user and other persons or damage to the equipment or other objects. The appliance is intended to operate in hot air circulation heating systems. Any other use must be considered improper.

responsible for the risk. Use according to the intended purposes also includes careful compliance with the instructions in this manual.

1.3 - WATER TREATMENT (see specific booklet)

• The hardness of the feed water conditions the frequency at which the domestic hot water exchanger must be cleaned.

• If the water has a hardness greater than 15°f, we recommend using water softeners, chosen according to the characteristics of the water.

• We recommend checking and cleaning the domestic hot water exchanger at the end of the first year of use and every two years thereafter; on this occasion, also check the state of wear of the anode.

1.4 - INFORMATION FOR USER OR SYSTEM MANAGER

• The User or system manager must be instructed concerning the use and operation of his heating system, especially:• Give the User or system manager these instructions, as well as the other appliance documents contained in the envelope inside the packaging. The User or system manager must keep this documentation for future consultation. • Inform the user or system manager about the importance of the air vents and the flue gas exhaust system,

highlighting their essential features and the absolute prohibition of modifying them. • Inform the user or system manager concerning control of the system's water pressure as well as operations

to restore it. • Inform the user or system manager concerning correct control of temperatures, control units/thermostats

and radiators to save energy.• Remember that the system must receive regular maintenance once a year and a combustion analysis must be performed according to the schedule prepared based on standards in force.• Should the appliance be sold or transferred to a new owner or if you move and leave the appliance, always make sure that the instruction booklet accompanies it in order to be consulted by the new owner and/or installer.

1 GENERAL INFORMATION

Attention: this manual contains instructions for the exclusive use of the professionally qualified installer and/or maintenance technician in compliance with current legislation.The user is NOT qualified to intervene on the boiler.The manufacturer will not be held liable in case of damage to persons, animals or objects resulting from failure to comply with the instructions contained in the manuals supplied with the boiler.

Firex shall not be held liable for any damage resulting from improper use; in this case the user is fully

4

General information

1.5 - SAFETY WARNINGS

ATTENTION!The appliance must be installed, adjusted and maintained by professionally qualified personnel, in compliance with standards and provisions in force. Incorrect installation can cause damage to persons, animals and objects for which the manufacturer cannot be held responsible.

DANGER!NEVER attempt performing maintenance or repairs on the boiler on your own initiative. Any work must be done by professionally qualified personnel. We recommend stipulating a maintenance contract.Insufficient or irregular maintenance can jeopardise the operating safety of the appliance and cause damage to persons, animals and objects for which the manufacturer cannot be held responsible.

Modifying parts connected to applianceDo not modify the following parts: - the boiler - the air, water and electrical current lines - the flue gas pipe, safety valve and heating water drain pipe - the construction parts which affect the operating safety of the appliance.

Attention!To tighten or loosen the screwed fittings, use only appropriate fixed spanners.Non-compliant use and/or inappropriate tools can cause damage (e.g. water leakage).

Explosive and easily flammable substancesDo not use or store explosive or easily flammable materials (e.g. petrol, paints, paper) in the room where the appliance is installed.

1.6 - TECHNICAL DATA PLATE

The technical data plate is adhesive and is included in the document case; it must be applied by the installer on the outside of the casing.The serial number of the boiler is on the riveted plaque on the front plate of the body (front right top side).

5

General information

1.7 - GENERAL WARNINGS

The instruction booklet is an integral and essential part of the product and must be kept by the user or system manager.

Read the warnings contained in this instruction booklet carefully as they provide important guidelines regarding installation, use and maintenance safety.

Keep the booklet with care for further consultation.

Installation and maintenance must be performed in compliance with standards in force according to the instructions of the manufacturer and by qualified and certified personnel in compliance with law.

By professionally qualified personnel we mean: personnel with specific technical skill in the field of heating system components for civil use, domestic hot water production and maintenance. Personnel must have the qualifications provided for by current legislation.

Incorrect installation or improper maintenance can cause damage to persons, animals or objects for which the manufacturer is not responsible.

Before performing any cleaning or maintenance, disconnect the appliance from the energy mains by acting on the switch of the system and/or through the specific cut-off devices.

Do not obstruct the terminals of the intake/exhaust ducts.

In case of failure and/or malfunctioning of the appliance, switch it off and do not try to repair it or intervene on it directly. Contact only personnel qualified in compliance with law.

Any repairs must be performed solely by personnel authorised by Firex using original spare parts only. Failure to comply with the above can jeopardise the safety of the appliance.

To guarantee appliance efficiency and its correct operation, yearly maintenance must be performed by qualified personnel.

Should you decide not to use the appliance, parts entailing potential sources of hazard must be made safe.

Should the appliance be sold or transferred to a new owner or if you move and leave the appliance, always make sure that the instruction booklet accompanies it in order to be consulted by the new owner and/or installer.

Only original accessories must be used for all appliances with optionals or kits (including electric).

This appliance is intended solely for the use for which it was expressly designed. Any other use is to be considered improper and therefore dangerous.

6

Technical features and dimensions

2.1 - TECHNICAL FEATURES

The heat generator mod. FIREX is a steel boiler running with natural wooden logs, total gasification, flame inverted, with the combustion chamber under negative pressure.

It comes in the following models:

FIREX 34 FIREX 45FIREX 55

The FIREX boiler is complete with all the safety and control devices required by relevant standards.

DESCRIPTION OF COMPONENTS:• Steel boiler body with combustion chamber partially

covered with refractory material.• Burner in refractory material.

2 TECHNICAL FEATURES AND DIMENSIONS

• Horizontal smoke ducts.• Front door for loading wood covered with refractory

material.• Bottom door covered with refractory material, complete

with combustion air adjustments and fitted with flame sight glass.

• Rear smoke chamber with side inspection and ash removal doors.

• Flue gas evacuation with intake fan.• Safety heat exchanger. • Boiler body insulated with 50 mm thick mineral wool

panels.• Powder painted sheet steel casing.

PANEL BOARD COMPONENTS:• Main switch with light indicating presence of power.• Boiler thermometer. • Safety thermostat for boiler overheating.• Boiler temperature adjustment thermostat.

2.2 - HYDRAULIC DIMENSIONS AND CONNECTIONS

fig. 1

1. Panel board2. Primary air adjustment 3. Secondary air adjustment4. Flame sight glass 5. Cleaning doors6. Rear smoke chamber7. Loading door8. Fan9. Bottom inspection and cleaning doorT1. Central heating flowT2. Central heating returnT3. Safety thermostat probe bulb holder, operating thermostat probe, maximum, minimum, thermometerT4. Fitting for possible bulb holder thermal discharge valve probeT5. Chimney connectionT6. Safety heat exchanger connectionsT7. Boiler drain

DIMENSIONSABCDEFG

510680

610680

610880

1230 138019081

19078

1025628

138019081

11501150628 828

(mm)(mm)(mm)(mm)(mm)(mm)(mm)

CONNECTIONS T1 - T2T5T6T3 - T4 - T7

UNI ISO 228/1(Ø mm)

UNI ISO 228/1

G 1¼150G ½G ½

G 1½200G ½G ½UNI ISO 228/1

H 65 65(mm)

G 1½200G ½G ½

65

FIREX 34 FIREX 45 FIREX 55

7


MODELS FIREX 34 FIREX 45 FIREX 55

MAXIMUM NOMINAL OUTPUT* (kW) 28.23 35.1 45.2

FURNACE MAXIMUM OUTPUT (kW) 34.65 43.04 55.45

* Power achieved with good quality wood with 15% humidity content.

WATER SIDE PRESSURE DROPS (10K)

WATER SIDE PRESSURE DROPS (20K)

BOILER WATER CONTENTEMPTY BOILER WEIGHTMAXIMUM OUTPUTOUTPUT IN STAND-BY

BOILER CLASS ACCORDING TO EN 303-5

(m.w.c.) 0.05 0.05 0.050.40.30.2(m.w.c.)

(l)(kg)(W)(W)

59

36316386

7147516386

9349716386

3 3 3

DURATION OF COMBUSTION

WOOD STORAGE VOLUME

MAX OPERATING PRESSURE

LOADING OPENINGLOG LENGTH

(h) 5 6 6

218160108(l)

(bar)

(mm)(cm)

3

334 x 41950

3

434 x 51950

3

434 x 51970

NOISE LEVEL (dB) <50 <50 <50

MINIMUM DRAUGHT REQUIRED BY CHIMNEY (Pa) 16 16 20

MIN. FLOW TEMPERATURE (°C) 75 75 75

MAX. FLOW TEMPERATURE (°C) 85 85 85

MIN. RETURN TEMPERATURE (°C) 55 55 55

NOMINAL LOADING FLUE TEMPERATURE (°C) 284 279 283NOMINAL LOADING FLUE GAS MASS FLOW RATE (kg/s) 0,02 0,024 0,031

EFFICIENCY (%) 81.5 81.6 81.5

O2 (%) 5.77 5.15 6.26

CO2 (%) 13.86 13.70 13.49

2.3 - TECHNICAL DATA

CO 10% (mg/Nm3) 510 555 584

CO 13% (mg/Nm3) 369 402 423

NOx 10% (mg/Nm3) 223 217 232

NOx 13% (mg/Nm3) 162 157 168

Hc 10% (mg/Nm3) 15 11 16

Hc 13% (mg/Nm3) 11 8 12

Dust 10% (mg/Nm3) 42 43 44

Dust 13% (mg/Nm3) 31 31 32

FUEL CHARACTERISTICS See par. 4.2 - 4.3 - 4.4

THERMAL STORAGE VOLUME(If Qmin > 30% of Qn)

(l) 1550 1930 2486

MAX. SUPPLY WATER TEMPERATURESAFETY HEAT EXCHANGER

(°C) 15 15 15

SUPPLY WATER PRESSURESAFETY HEAT EXCHANGER

(bar) 2 2 2

BOILER OPERATION WITH FAN WITH FAN WITH FANCOMBUSTION CHAMBER OPERATION UNDER NEGATIVE PRESSURE UNDER NEGATIVE PRESSURE UNDER NEGATIVE PRESSUREOPERATION IN CONDENSATION NO NO NO

8


2.4 - MAIN COMPONENTS

1. Panel board2. Top cover3. 2 side panels4. Anti-smoke door5. Wood storage door with refractory material and gasket6. Primary and secondary air adjustment unit7. Fan8. Combustion chamber door with refractory material, gasket, flame sight glass9. Thick steel combustion chamber10. Heat exchange fin11. Boiler drain 12. Safety heat exchanger13. Mineral wool boiler body insulation14. Steel boiler body15. Burner built with refractory material with bars and grate16. Smoke chamber17. By pass M Heating system flowR Heating system return

fig. 2

N.B.: The fire bars and the refractory steel grate are subject to wear; it is therefore advisable to carry out an annual inspection to prevent faulty boiler operation.

2.5 - GENERAL

A BRIEF SUMMARY OF INVERTED FLAME COMBUSTION

Everybody knows that to make a match last it must be held with its head upwards. This is because it is necessary that the flame, in its convective motion, does not meet another fuel in addition to the one which has generated it. As in residential heating the fuel is in the form of wood logs which are loaded from the top, the flame has to go in the opposite way, i.e. downwards.Natural draught is a source of depression which varies greatly depending on the type of chimney, on weather conditions, on the type of fuel, etc. Therefore it is necessary to integrate it with forced ventilation in order to stabilise it.

By fitting a fan it is possible to considerably reduce the section of the gas ducts on the grate and furthermore there are no problems with cold starts.The small grate permits a more controlled passage of combustion air, contrarily to what happens with large traditional grates.The air can be perfectly dosed because the grate, covered with burning wood, has the same crossing resistance and thus the combustion will be always optimal..Firex has already used this principal for many years with the Gasogen boiler.

9


fig. 3

FIREX BOILER STRUCTURE

The boiler body is composed of two oval elements placed one inside the other, so that a cavity of water (fig.3) is created between the two.The large capacity wood storage has a special thermal and mechanical high resistance refractory press, for the purpose of keeping the by-pass area dry in all operating conditions.The following parts can be distinguished (fig.3):

1. Wood storage, drying zone2. Gasification zone3. Embers zone4. Burner in refractory material5. Combustion chamber6. Heat exchange surface7. Cradle in refractory material8. Boiler water9. Safety heat exchangerM System hot water flowR System return

GASIFICATION ZONE (2)Gasification takes place in the lower part of the firewood storage.It is very important that gasification is as regular as possible, so as not to overload the burner with gas.Gasification speed depends on the amount of wood and the dimensions of the drying zone. Generally, it is better to use large logs if they are dry and small logs if the wood is moist. The quantity of primary air, proportional to the delivered output, is regulated via the adjustment system.

EXCHANGE SURFACE (6) Operating on wood and without very high sulphur percentages, it is important to achieve very low flue temperatures to improve water efficiency. Accordingly, a dry-passage exchange surface was adopted (fig. 4), which is already well-tested for diesel-fired boilers operating with low temperature water, providing low flue temperatures without the risk of condensation.The surfaces of the dry ducts "A" (fig. 4) have cuts in them, to avoid the problem of expansion.The solid combustion residues (ashes), that fall onto the high temperature cradle built with refractory material (fig. 3, pos. 7), will become, with time, increasingly lighter until they are carried by the gas speed and deposited in the lowest area of the rear smoke chamber, where they will be removed from during cleaning.

fig. 4

10


REFRACTORY BURNER (4)The burner is made with refractory stone (fig. 3, pos. 4.) This stone has a central rectangular opening that the flame passes through.The embers lie directly on the stone which divides the fire wood storage from the lower combustion chamber. Furthermore the main refractory stone has a rectangular seat in which the opportunely grooved thermal steel fire bars are placed (fig. 5, pos. 2), which receive the secondary air from a front distributor.The embers are prevented from falling by refractory steel rings. The combustion gases, poor in oxygen and still rich in carbon not yet combined, travel across the embers and enter the opening in the centre of the main stone.Inside this pre-combustion chamber, the gases combine with the pre-heated secondary air coming through the grooves of the two cast iron fire bars.This will produce a high oxygen rich bluish-coloured flame. This flame comes out from the oval opening and invades the combustion chamber.Due to the high temperatures the refractory burner will become a bright red colour.

COMBUSTION CHAMBER (5)Combustion is optimised by increasing the flame temperature and producing a strong turbulence in the bottom chamber.For this reason the flame, in addition to not touching cold walls irrigated by water, bounces and is divided on a semicircular cradle which rests on the lower exchange surfaces, which, aside from delimiting the smoke ducts, also has the task of collecting the ashes and possible embers. The flames, after having bounced off the walls of the bottom area and the refractory ones, direct themselves with a whirling motion towards the front part of the combustion chamber and enter the flue ducts. Combustion will be complete and clean and the dominant colour will be that of the ashes: white.

M = Hot water flowR = System returnP = Primary airS = Secondary airF = Flue gas

fig. 6

fig. 5

1. Refractory steel grate2. Refractory steel fire bars

11


3 INSTRUCTIONS FOR INSTALLATION

3.1 - GENERAL WARNINGS

ATTENTION!This boiler is intended solely for the use for which it was expressly designed. Any other use is to be considered improper and therefore dangerous.This boiler heats water at a temperature lower than the atmospheric pressure boiling temperature.

ATTENTION! The appliances are designed to be installed inside suitable rooms or technical spaces only. The appliances cannot be installed or operate outdoors. Outdoor installation can cause malfunctioning and be dangerous. Choose specifically designed appliances for outdoor installation.

Before connect ing the bo i le r, have professionally qualified personnel:a) Thoroughly wash all the piping of the system

to remove any residue or impurities which could jeopardise proper operation of the boiler.

b) Check that the chimney/flue has an appropr ia te draught , w i thout any bottlenecks, and that no exhausts from other appliances are inserted, unless the flue has been implemented to accommodate several utilities according to specific standards and prescriptions in force. Only after this check can the fitting between the boiler and chimney/flue be mounted.

ATTENTION!The appliance must be installed by a qualified technician with the technical-professional requirements according to law 46/90 which, under his own responsibility, guarantees compliance with standards according to good practice rules.

The boiler must be connected to a central heating system and/or domestic hot water production network compatible with its efficiency and output.

3.2 - INSTALLATION STANDARDS

The FIREX boiler is designed for wood-burning operation.

It must be installed according to the following standards:

M.D. December 1 1975.Safety standards for appliances containing hot pressurised liquids.FIELD OF APPLICATION: thermal potentials greater than 35 kW (30,000 kcal/h).

L.D. Num. 93 of February 25, 2000.Implementation of directive 97/23/EC (P.E.D.) concerning pressurised equipment.FIELD OF APPLICATION: appliances fed by liquid fuels (naphtha, diesel oil, combustible oil) and solids.

Standard UNI 10412 of December 1994.Hot water heating systems. Safety prescriptions.FIELD OF APPLICATION: thermal potentials greater than 35 kW (30,000 kcal/h).

M.D. Num. 37 of January 22 2008, the "Regulation setting forth amendments concerning the installation of systems in buildings"FIELD OF APPLICATION: without thermal potential limits.

Standard UNI 10847 of March 2000.Single flue systems for generators fed by solid and liquid fuels. Maintenance and control. Guidelines and procedures.FIELD OF APPLICATION: appliances that run on solid and liquid fuels.

LAW January 9, 1990 N° 10 and relative applicative regulation by Italian Presidential Decree. 412 of 26 August 1993 (and subsequent modifications), Italian Presidential Decree n°551 of 21.12.1999.Regulation with amendments to Italian Presidential Decree. n° 412 concerning design, installation, operation and maintenance of thermal systems in buildings, in order to reduce energy consumption.FIELD OF APPLICATION: without thermal potential limits.

Law n°186 of 01.03.1968 Installation standard IEC 64-8 / II ed.Electric systems using rated voltage no greater than 1000 V AC and 1500 V DC.

Installation standard IEC 64-8 / II ed.Electric systems in buildings intended for residential and similar use.

Standard UNI 10683 - September 2005Heat generators running on wood or othersolid biofuels. Installation requirements.

Standard UNI 8065/89 - June 1989Treatments and limit characteristics of the water used in for heat-ing systems running on hot-water, DHW, over-heated water and low-pressure steam, with the aim of optimising efficiency, safety and minimising energy consumption.

LAW July 13 1966 Num. 615 and relative applicative regulation by Italian Presidential Decree. 1391 of December 22, 1970 (and subsequent amendments).Provisions against environmental pollution (systems fed with solid and liquid fuels).FIELD OF APPLICATION: thermal potentials greater than 35 kW.

12


3.3 - PACKAGING

FIREX boilers are delivered unassembled: the casing, the fan, the panel board, the handles and cleaning accessories are all shipped in separate boxes (fig. 7).

After having removed packaging, make sure that the supply is complete and undamaged.If in doubt, do not use the appliance and contact the supplier.

The packaging elements (cardboard boxes, straps, plastic bags, etc.) out of the reach of children as they are potential sources of danger.Firexwill not be held liable for damage to persons, animals or objects due to failure to comply with the instruction above.

Description of packs:

1. Boiler body2. Package containing casing and boiler insulation3. Package containing the panel board4. Package containing flue extraction fan5. Package containing: air intake header, smoke chamber

inspection covers, handles, screws, flame control mirror, cleaning accessories. This package is sent inside the wood storage compartment (top door).

The document envelope, inserted in the wood storage, contains:- Hydraulic test certificate (> 35 kW) - System (< 35 kW) or central unit (> 35 kW) booklet - User/System manager operating instructions for the sys-

tem- Installation and maintenance instruction booklet- Warranty- Coupons for returned spare parts- Adhesive plate with technical data- Adhesive plate with local ventilation requirements (< 35 kW)

If the boiler is stored for long periods, it should be adequately protected.

fig. 7

3.4 - TRANSPORT

To make it easier to load and unload the boiler, it has special "G" hooks (fig. 7) on top of it, for lifting.

13

Installation instructions

3.5 - POSITIONING IN BOILER ROOM

The FIREX boiler does not differ from a normal solid fuel fired boiler; therefore there are no particular installation codes of practice other than the safety provisions foreseen by standards in force.The installation room must be properly ventilated by openings with a total minimum surface of no less than 0.5 m².The boiler room must have a minimum volume of > 15m3.The negative pressure measured during operation between the indoor room and the outdoor environment must be lower than 4 Pa.To make it easier to clean the smoke circuit, in front of the boiler, there must be a free space no less than the length of the boiler. Check at least that the doors can open by 90° without meeting any obstacles.The boiler can be placed directly on the floor, as it is equipped with a self-supporting frame. Nevertheless, in case of installation in very damp boiler rooms, it is preferable to provide cement support.When installation has been performed, the boiler must be in a horizontal position and stable so as to reduce possible vibrations and noise.It is always necessary to leave enough free space behind the boiler so that the fan can be accessed and serviced.

fig. 8

3.6 - CONNECTING BOILER TO SYSTEM

Attention! Make sure that there are no mechanical tension points while connecting the pipes to avoid the risk of leakage!

Heating flow and return pipes must be connected to the boiler at the respective fittings as indicated on page 6.

For the dimensioning of the heating circuit pipes, you must take into account pressure drops caused by radiators, thermostatic valves, radiator stopping valves and by the configuration of the system.The laying of the pipes must be designed taking every necessary precaution to avoid air pockets and to facilitate continuous degassing of the system.

Make sure that the pipes of the water and heating system are not used as earthing electrodes of the electric or telephone system. They are absolutely not suitable for this type of use. Serious damage could result for the piping, boiler and radiators in a short amount of time.

14


3.7 - CONNECTION TO THE FLUE

To connect the flue gas exhaust pipe, local and national standards must be respected (see UNI Standards).

The chimney is essential to good boiler operation: accordingly, the chimney needs to be water-proof and well-insulated.Old or new chimneys, built without respecting the specific requirements, can be recovered by “piping” the chimney itself.It will be necessary to introduce a metallic pipe inside the existing chimney and insulate the space between the metallic pipe and the chimney.Chimneys made of prefabricated blocks must have perfectly sealed joints to avoid that flue condensate smudge the walls due to permeation.The entrance to the chimney should be at a 45° angle.At the base of the chimney a flue inspection opening has to be made. It is recommended to insulate the pipe connecting to the chimney to reduce heat loss and noise.

The combustion products must be released from the roof; IT IS FORBIDDEN to use a direct wall exhaust system.

1. Boiler2. Flue outlet connection 3. Ash collection chamber 4. Chimney 5. External flue lining

6. Prefabricated blocks7. Insulation8. Flue9. Draught limiter/adjuster

Use only exhaust pipes suitable for the type of fuel used. The supplier will have no contractual or extra-contractual liability for damage caused due to incorrect installation and use and anyway failure to comply with the instructions provided by the manufacturer.

When performing replacement installations, ALWAYS replace the flue gas exhaust accessory as well.

The flue must comply with standards in force.

For correct boiler operation, the chimney must provide the correct draught.- Low draught reduces efficiency with consequent flue

emissions during the loading phase.- High draught considerably increases the flue temperature

and consequently increases the boiler flow temperature, triggering the circuit breakers.

To avoid all of this, it is essential to install a draught limiter/adjuster.

fig. 9

15


3.8 - CONNECTION TO THE SAFETY HEAT EXCHANGER DRAIN

Solid fuel fired boilers must be installed with the safety devices foreseen by relevant laws in force.For this purpose FIREX boilers are equipped with a safety exchanger.

A thermal discharge valve must be installed on the safety heat exchanger by the installation technician, with a control bulb that set up inside the sheath located on the rear side of the FIREX boiler.

Attention!The input or output can be inverted as long as the valve is installed on the cold water intake.

Provide a drain pipe with a funnel and a siphon leading to an appropriate drainage at the heat exchanger outlet. This drainage must be controlled on sight.

Attention!If this precaution is not taken, triggering of the thermal discharge valve can cause damage to persons, animals and objects for which the manufacturer cannot be held responsible.

fig. 10

fig. 11

SUPPLY

DISCHARGE

DISCHARGE

DISCHARGE

SUPPLY

SUPPLY

CORRECT ASSEMBLY

INCORRECT ASSEMBLY

16


3.9 - RECIRCULATION PUMP

For correct boiler operation, a recirculation pump must be installed.The recirculation pump, supplied in an optional kit, must be connected is indicated in the figure.The recirculation pump must guarantee a return temperature of no more than 55°C.It must be controlled exclusively from the boiler control panel. If it is not installed, besides limiting the boiler's lifespan, it will invalidate the warranty.

ATTENTION!The hardness of the mains water supply conditions the boiler's lifespan.It is always recommended to treat water with a hardness greater than 15°f.

Firex has designed a "RECIRCULATION KIT FOR OPERATION WITH STORAGE TANK" for its customers.The kit is supplied as an option and is available by indicating the model of your boiler.

fig. 12

3.10 - ASSEMBLY INSTRUCTIONS

Fan assembly

Fit the fan to the smoke chamber.

fig. 13

IMPORTANT!When the fan is being installed the smoke chamber gasket must be perfectly sealed, otherwise the wall of the gasket would deform, causing serious damage to the impeller and/or fan motor.

This issue occurs even more quickly the more the wood loading door is opened.

17


fig. 14

fig. 15

12

3 4

Install the body insulation by making a suitable cut where the top flow fitting is.

- Wrap the plastic strap around the mineral wool insulation and insert one of its ends in the locking slot as shown in detail 1.

- Holding the end of the strap already inserted, proceed with the other end by folding the plastic pin inward as shown in detail 2.

- Pull the two ends of the strap (as shown in details 3 and 4) until the strap adheres to all the mineral wool covering the boiler body.

It is recommended not to overstretch the strap; an excessive crushing of mineral wool would cause a non-homogeneous insulation.

In case of maintenance it is possible to remove the strap by acting on the locking slots.

Insulation and casing assembly- Detail “A”: assemble the knob pos.

4 on the top door closing handle. Mount the screw and nut on the top

door and screw the knob on (pos. 1, 2, 3).

- Detail “B”: assemble the air header pos. 2.

Primary and secondary air draught adjustment is described on page 30.

- Detail “C”: assemble the screw and nut on the bottom door and screw the knob on (pos. 1, 2, 3).

- Detail “E”: assemble the smoke chamber inspection doors.

- Attach the flame control mirror (pos. 6) to the sight glass on the bottom door.

- Install the body insulation by making a suitable cut where the top flow fitting is.

fig. 16

Fasten the micro-switch to the inside of the front plate and adjust the axis of the thrust washer so that it is controlled every time the top wood loading door is closed.

18


- Hook the left side panel onto the body of the boiler (pos. 1).

- Hook the right side panel (pos. 2) onto the body of the boiler.

- Put the panel board and the casing cover together (on the ground) (pos. 3, 4, 5, and 6).

- Attach the rear cable clamp support profile to the top panel, pos. 7.

- Open the panel board, turning the two side screws with a screwdriver.

Lift the cover from the back, rotating it frontwards. Pass all of the thermostat capillaries by unrolling them

carefully through the two rectangular slots on the base of the panel board, namely: the fan/s connecting cable (output), the door opening micro-switch cable (input) and the connecting cable to the power line (input).

- Place the casing cover on the boiler and direct the end of the capillaries towards the rear of the boiler.

- Attach the boiler's TECHNICAL DATA plate and, only for models < 35 kW, the LOCAL VENTILATION STANDARDS plate, on the right side of the casing, once this area has been cleaned and degreased with a suitable product.

Remove the protective film from the plate and apply it making sure it sticks perfectly.

Do not remove the plates as they would no longer stick.

fig. 17

fig. 18

The thermostat bulbs are identified by labels attached to their respective capillaries; accordingly, be careful not to tear any of these labels during any maintenance operations. A) Set up the operating thermostat bulb (Te), the maximum

thermostat bulb (Tmax), the minimum thermostat bulb, (Tsc), the safety thermostat bulb (Ts) and the thermometer bulb in the dedicated bulb holder.

B) Attach the fan socket support bracket pos.1 to the side of the casing using the 3 supplied self-tapping screws, and screw in screw pos. 2 against the smoke chamber.

Install the fan socket on the bracket pos. 3.

C) Plug the fan plug into the socket (detail 3).D) Set up the electrical connections for the loads and line as

illustrated in the diagrams contained in chapters 3.12 and 3.13.

Close the panel board.

Make sure the electrical cables do not come into contact with the smoke chamber. During operations, the chamber reaches high temperatures.

WORKING THERMOSTAT (Ts)

MINIMUM THERMOSTAT (Tsc)

THERMOMETER

CLAMPING SPRING

CONTACT SPRING MAXIMUM

THERMOSTAT (Tmax)

SAFETY THERMOSTAT (Ts)

19


3.11 - ELECTRICAL CONNECTIONS

General warnings

The electrical safety of the appliance is guaranteed only when it has been properly connected to an efficient earthing system carried out as intended by safety standards in force: pipes of the gas, water and heating systems are absolutely unsuitable as earthing electrodes.

It is necessary to verify this fundamental safety requirement. If in doubt, have the electric system carefully checked by professionally qualified personnel as the manufacturer is not liable for damage caused by failure to provide an earthing system.

Have professionally qualified personnel check that the electric system is adequate for the maximum power absorbed by the appliance, indicated on the data plate. Make sure in particular that the cross-section of the cables is suitable for the power absorbed by the appliance.

Adapters, multiple sockets and/or extension cords cannot be used to power the appliance.

Use of any type of component using electric energy requires the observance of some fundamental rules, such as: • do not touch the appliance with wet and/or moist parts of

the body and/or in bare feet; • do not pull the electric cables; • do not leave the appliance exposed to atmospheric agents

(rain, sun, etc.) unless expressly designed; • do not allow children or unskilled persons to use the ap-

pliance.

230V electric power supply connection

The general electrical connections are illustrated on page 21.

Boiler installation requires connection to a 230 V - 50 Hz electric mains: This connection must be set up according to standard, as intended by current IEC regulations.

Danger!Only a qualified technician may perform the electrical installation.Before performing connections or any type of operation on electrical parts, always disconnect electrical power and make sure that it cannot be reconnected accidentally.

Remember that a bipolar switch must be installed on the boiler power line with over 3 mm between contacts, easy to access, making maintenance quick and safe.

The power cable must be replaced by authorised technical personnel. Failure to comply with the above can jeopardise the safety of the appliance.

Attention!

- Before opening the panel board, move the main switch (11) to pos. “0”!- Do not connect loads to the panel board which absorb more than 4A overall!

ApprovalsThe Firex panel board is CE-approved, in accordance with standard EN 60335-1.

Technical data plate and serial numebrThe identification plate of the panel board is glued on the base.

UseThis panel board must be used to operate a boiler intended to heat water at a temperature which does not exceed the boiling point when installed.

20


3.12 - STANDARD PANEL BOARD

The standard panel board (code 36749) operates semi-automatically and is delivered to the user in a cardboard box with the following standard equipment:- Limit switch for installation on the by-pass rod control mechanism (TKS) (see fig. 16).- 3-pole cable for the electrical connection of the fan.

The connection between the thermostat bulbs and boiler must be set up as illustrated in fig. 18.The connection between the panel and the loads (system pump, recirculation pump, fan, etc.) must be set up accord-ing to the general diagram in fig. 20.

Functional description:

Once the panel board is powered by the general switch pos. 11 and the system pump pos. 13, it is possible to turn the boiler on.Once the boiler is switched on, close the loading door; accordingly, micro-switch TKS, which is controlled directly by the closing of the top door, will reset the timed relay which will “start counting”.The standard relay setting time is 30 minutes, which can be increased by 30 minute increments.Thermostat Tsc (minimum thermostat), which being calibrated to 65°C is not fulfilled at start-up, stops system pump operation until this temperature is reached. If the boiler does not reach 65°C within the set amount of time, the timed relay will stop the fan.This can be a symptom of the boiler not starting up, or an insufficient wood load.To avoid this issue it is possible to increase the timed relay trigger time (an operation which must be carried out by qualified staff) or the wood load must be increased.If the boiler switches on as usual, the system pump will start up when it reaches 65°C.The operating thermostat pos. 32 will make the boiler operate in “automatic” by intervening on fan/s operation.This same thermostat will stop the fan when the set operating time is reached.When the boiler overheats excessively (over 90°C), and if the thermal discharge valve triggers with a delay (note that with solid-fuel boilers, given the thermal inertia, installation of this valve is compulsory), the maximum thermostat will automatically start up Tmax which, by bypassing the micro-switch TKS, the thermostatic control of the system pump Tsc and the switch that starts up the pump itself Ipi, will discharge the thermal inertia of the boiler onto the system. This situation could lead to unwanted heating of the system's radiant elements, even if the ambient conditions do not request it. The safety thermostat is installed on the fan control line Ts, stopping fan operation if the temperature reaches 100°C (the safety limit temperature).It is possible to reset this thermostat by unscrewing the cap pos. 31 and pressing the button below. Any ambient thermostat can be connected to clamps 19 and 20 once the jumper that joins them has been taken off. Recirculation pump Pr must be connected to clamps 10 and 11.

21


32 Working thermostat41 General fuse (4A)42 Boiler thermometer

11 Main switch 12 Fan switch13 System pump switch31 Safety thermostat

ELECTRICAL DIAGRAM KEY Ph NF1 IG Ipi Iv LL Pi Pr

Phase (230V ~50Hz)NeutralGeneral fuse (max 4A)Main switch with indicator lightSystem pump switchFan switchLine lampSystem pumpRecirculation pump

Rt R1 Te TKS Tmax Ts Tsc V

Timed relayRelayWorking thermostat (75°C÷85°C)By-pass rod micro-switchMaximum thermostat (90°C)Safety thermostat (100°C)Minimum wood thermostat (65°C) Fan (i)....reference to panel front

fig. 19

fig. 20

22


3.13 - HYDRAULIC AND ELECTRICAL CONNECTION DIAGRAMS

Attention! The diagram below is indicative and can be customised.For special requirements, please contact our After-Sales Service.

System with FIREX and PUFFER storage model boiler, DHW production with coil type boiler and dedicated loading pump.

KEY:PrRMVPMVPiVACS VE IR SVATm Tb KRF

recirculation pump (if not installed, the warranty is null and void)anti-condensation thermostatic valvestorage thermostatic valve (optional)heating system pumpDHW storage tank loading pumpopen expansion vessel heating system distribution (loading)PMV thermostatic valve probe wood-fuelled boiler flow temperature probeDHW storage tank temperature porbeRMV anti-condensation thermostatic valve probe

fig. 21WOOD-FUELLED BOILER STORAGE TANK HEAT

EXCHANGERDOMESTIC HOT WATER

PRODUCER

SUPPLY

FAN

23


3.14 - FILLING THE SYSTEM

Attention!Do not mix the heating water with incorrect concentrations of antifreeze or anti-corrosion substances! This could damage the gaskets and cause noise during operation. Firex will not be held liable for damage to persons, animals or objects due to failure to comply with the above instruction.

After completion of all the hydraulic connections, fill the boiler and proceed with the inspection of soundness of all the connections.This operation must be performed carefully, respecting the following phases:- open the radiator air release valves;- open the system filling tap gradually, making sure that the

automatic air release valves installed on the system work properly;

- close the radiator air release valves as soon as water comes out;

- check the pressure gauge until pressure reaches approx-imately 1 bar (this is valid only for installations equipped with a closed expansion vessel - consult local regulations if this is allowed); for installations equipped with an open expansion vessel, restoration is carried out automatically via the same expansion vessel;

- close the system filling tap and bleed air once again through the radiator air release valves;

- make sure that all the connections are watertight;- after commissioning the boiler and bringing the system

to the operating temperature, stop the pumps and repeat the air bleed operations;

- let the system cool down and, if necessary, bring the water pressure back to 1 bar (this is valid only for installations equipped with a closed expansion vessel - consult local regulations if this is allowed); for installations equipped with an open expansion vessel, restoration is carried out automatically via the same expansion vessel.

NOTEIn systems equipped with closed expansion vessel, where allowed, the water pressure in the heating system - with the system cold - must not drop below 1 bar; open the filling tap when pressure is too low.This operation must be performed with a cooled system. The pressure gauge fitted on the system allows you to read circuit pressure.

NOTEIf the boiler was without electric power, after a certain idle period, the pump could be blocked. Before turning on the main switch, the pump must be unblocked by operating as follows:Introduce a screwdriver in the hole below the protective screw in the centre of the pump intended for this purpose and turn the pump shaft clockwise. After having unblocked the pump, tighten the protective screw and make sure there is no water leakage.

fig. 22

ATTENTION! After removing the protective screw, a small amount of water could leak out. Dry off all wet surfaces before powering the boiler.

24


4.1 - COMMISSIONING

Preliminary checks

C o m m i s s i o n i n g m u s t b e d o n e b y professionally qualified personnel. Firex will not be held liable for damage to persons, animals or objects due to failure to comply with the above instruction.

Before commissioning the boiler, check that:

- installation fulfils UNI standards regarding the gas part of any back-up boiler and IEC standards for the electrical part;

- the adduction of combustion air and flue gas evacuation are performed correctly according to that laid down by standards in force;

- the boiler is equipped with all safety and control devices prescribed by current standards;

- the power supply of the boiler is 230V - 50Hz;

- the system has been filled with water;

- any system shut-off gate valves are open;

- the gas feed valve of a possible auxiliary boiler, is open;

- the external main switch is connected;

- the thermal discharge valve of the wood heater is not blocked and is connected to the sewer system drainage;

- there is no water leakage;

- ventilation conditions and minimum distances are guar-anteed to perform maintenance.

Switching boiler on and off

To switch the boiler on and off, see the “SYSTEM USER/MANAGER/OPERATING INSTRUCTIONS” booklet.

Information for the system user or manager

The system user and/or manager must be instructed concerning the use and operation of his heating system, in particular:• Give the system user the “SYSTEM USER/MANAGER

OPERATING INSTRUCTIONS”, as well as the other ap-pliance documents inserted in the envelope inside the packaging. The system user and/or manager must keep this documentation for future consultation.

• Inform the system user and/or manager about the impor-tance of the air vents and the flue gas exhaust system, highlighting their essential features and the absolute prohibition of modifying them.

• Inform the system user and/or manager concerning control of the system's water pressure as well as operations to restore it.

• Inform the system user and/or manager concerning correct control of temperatures, control units/thermostats and radiators to save energy.

• Remember that the system must receive regular main-tenance at least once a year and a combustion analysis must be performed in the timetable foreseen by standards in force.

• Should the appliance be sold or transferred to a new owner or if you move and leave the appliance, always make sure that the instruction booklets accompany it in order to be consulted by the new owner and/or installer.

BOILERSTART-UP

4

25


4.2 - FIREWOOD

Wood is formed mainly by cellulose and lignite. It also contains other substances, such as resin (fir - pine), tannin (oak - chestnut) and, obviously, a large quantity of water.Good quality woods are oak, ash, beech, maple and fruit trees, except cherry; medium quality wood is: chestnut and birch; sufficient quality wood: lime tree, poplar and willow. Resinous trees

are, normally, second-rate quality fuels.Wood is therefore an extremely heterogeneous fuel, due to different essences (beech, oak, fruit, resinous), different moisture content, and due to different shapes and dimensions.Boiler operation will inevitably be effected by all these factors. Especially by the log dimensions, the moisture content and the way wood is loaded in the boiler.

4.3 - WOOD MOISTURE

The calorific value of the different types of wood depends on their moisture content, as illustrated in the table. Boiler output and autonomy will diminish as the moisture increases. The table provides the power reduction factor based on the humidity of the wood being used. The heat output of the FIREX boiler is calculated for wood with a 15% moisture content.As an example, wood which has been dried for 2 years in a sheltered area has a 25% moisture content.Example:humidity of the wood being used = 30%output = nominal output x 0.79

Correction factors for wood humidity

% OF HUMIDITY

CALORIFIC VALUEkcal/kg

CORRECTION FACTOR

1520253035404550

3,4903,2503,0102,7802,5402,3002,0601,820

10.930.860.790.720.650.590.52

4.4 - FIREWOOD DIMENSIONS

The dimensions, together with the moisture content, contribute to determine the boiler’s output. Small pieces (with a length, however, conforming to indications indicated hereby) are more easily flammable and therefore have the tendency to increase the boiler’s output and therefore to reduce its autonomy. Moreover, they

fall with greater facility, in the lower chamber, reducing the risk of the formation of “bridges”. The so-called “bridge” is an empty space in the firewood storage compartment, where unburnt wood logs remain. In this case the bed of embers is not fed with continuity and the refractory burner’s slot is uncovered. In these conditions, preferential air ducts are created with a very small flame due to an excess of air.

4.5 - CHECKS AT COMMISSIONING

GENERAL CHECKSUpon commissioning: make sure the system is full of water and well deaerated, that the safety exchanger is connected to the water mains by the thermal discharge valve (fig. 10, page 16), that the chimney is working efficiently, that the electrical connections have been made (chap. 3.12 and 3.13) and that the recirculation pumps and boiler are not blocked. Also make sure that the grate and bars are in place.

THE BYPASSThe bypass is a direct passage between the firewood storage and the chimney.By opening the wood loading door, the by-pass allows the accumulated flue in the storage compartment to be extracted and sent directly to the chimney.The bypass, in conclusion, allows the smoke to be discharged to the chimney without escaping from

the loading door when loading the wood or during lighting.Anyway, it is essential to open the loading door slowly and, as well, to rotate the anti-smoke flap (pos. 4, fig. 2) gradually so that the smoke is effectively suctioned.

BYPASS CONTROLDuring the installation stage and, in any case, before starting to use the boiler, check the tightness and then the operation of the bypass.Make sure the bypass rod works and that the micro-switch is positioned correctly. Check that the fan starts up as soon as the door opens.

26


4.6 - STARTING IGNITION

Make sure that the controls referred to in point 4.5 have been performed. Once the air has been adjusted in accordance with paragraph 4.7, close the bottom door and power the electric control board. The first ignition of the new boiler could be difficult

due to moist refractory cement casting.Accordingly, we advise opening the primary air well and lowering the secondary air.

Open the top loading door and place small pieces of dry wood crosswise on the main stone, above the central slot. Use highly flammable material, and avoid large and square logs.Light the wood using thin sheets of paper (newspaper or the likes). Approach the top door and turn on the fan.Wait a few minutes for the fire to catch and produce embers (5 - 10 minutes approximately).After a few minutes, if looking through the flame sight glass of lower door you see that the flame inversion is beginning, add other larger logs.Close the top door.Important: during the normal operation of the boiler, the bypass must always be perfectly closed.

The wood must have the following length:a) 50 cm (+ 1 cm, - 4 cm) for model FIREX 34b) 50 cm (+ 1 cm, - 4 cm) for models FIREX 34c) 70 cm (+ 1 cm, - 4 cm) for model FIREX 55

These measurements must be strictly observed.

As for good combustion it is essential that there is a uniform descent of the wood, it is necessary to ensure that the length of the wood logs introduced, their shape and the manner of loading does not prevent the regular descent of the fuel.The wood logs must be placed longitudinally and horizontally. No log should be tilted or placed sideways.Once you have checked flame inversion, it is possible to proceed with further loading (bear in mind that the primary and secondary air adjustment indications in the table are approximate).

FURTHER LOADING

Before loading wood once again, consume the previous one as much as possible.It can be reloaded when the bed of embers, in the firewood compartment, will be reduced to a thickness of about 5 cm.Open the loading door and the internal anti-smoke door slowly.It is necessary to use wood logs with the length stated in the previous paragraph.Place the new wood logs as described above.

fig. 24

fig. 23

1 Air adjustment unitS Secondary air adjustmentP Primary air adjustment

USEFUL TIPS, LOADING ERRORS

- Logs which are too long do not fall down properly and can cause "bridges".- Logs which are too short cause irregular air ducts, with consequent reduction in output and efficiency.- If the quality of the wood causes "bridges", it could become necessary to load logs cut in half so that the total length “L” is as indicated in the previous paragraph.To avoid the formation of "bridges", it is unadvisable to place logs against the side walls of the wood storage compartment. (see fig. 3).- Always open the upper door slowly, in order to avoid blowbacks and smoke formation.- During normal boiler operation, it is absolutely forbidden to open the lower combustion chamber door.

tagliare

=

=L

L

Cut

27


4.7 - COMBUSTION AIR ADJUSTMENT

PRIMARY AND SECONDARYAIR ADJUSTMENT

The FIREX boiler is equipped with a combustion air intake fan (pos. 16 fig. 2), a combustion air adjustment unit (pos. 1 fig. 23) and primary (pos.P fig. 23) and secondary air regulators (pos. S fig. 23).When commissioning the boiler, you need to

adjust the primary and secondary air, bearing in mind that the primary air determines the boiler heat output and therefore the amount of wood that is burned, and the secondary air completes the combustion. The following are the optimal adjustments of primary and secondary air using good quality wood (beech) and low moisture content (15%).

primary air secondary air pos. pos. FIREX 34 3÷4 ~1

FIREX 45 4÷5 1÷2

FIREX 55 3÷4 1÷2

For a proper air adjustment based on the type of wood used and its effective moisture level, it is necessary to observe the flame through the flame sight glass placed on the lower door. The flame should fill about two-thirds of the lower combustion chamber and gently caress the bottom cradle, without dragging too much ash and without noise.The flame will have an orange-pink-white colour, not too transparent and with the centre tending towards blue.To bring the flame to optimum conditions, you should then adjust the primary air by turning the knob (pos. P). Do the same for the secondary air (pos. S).

Example n.1Thick damp wood that is difficult for combustionS - Very closed (try to get the maximum dimension of the flame, but not of a reddish colour).P - Reasonably open in order to obtain a sufficient gasification.

Example n. 2Very inflammable wood logsS - Completely open.P - Slightly closed in order to keep gasification reduced, but sufficiently open to evacuate the ash that can close the combustion head.

GENERAL ADVICE

- Better performance will be achieved after two or three days of running. Refractory material must be cooked and the tar must encrust the upper walls of the wood storage compartment.

- The flame should have a good size and fairly fill the combustion chamber.

- The flame should not be too red (lack of secondary air S).- The flame should not be too blue (excess of secondary air S).- The flame should not be too noisy (excess of primary air P).- The flame should not be too small (lack of primary air P).- If the ashes do not go down well, increase the primary air (P).- If too many ashes fall, decrease the primary air (P).- If the chimney is smoky, open the secondary air (S) all the

way.- If smoke continues to escape, open secondary air (S) to a

maximum, closing the primary air (P) partially as well.

AIR ADJUSTMENT FAULTS

1) If the primary air is excessive, a lot of ash and small pieces of embers will fall. The flame is too fast, dry, has a cold colour and makes noise.The boiler is consuming a lot of wood and the door’s insulation is white.2) If the primary air is insufficient, the flame will be slow, hesitant, affected by air currents and by the chimney draught, very small, incapable of touching the lower cradle, with low ash production and the door’s refractory insulation will be dark coloured.3) If the secondary air is excessive. the flame will be small, of a bluish colour and very transparent.4) If the secondary air is insufficient. the flame will be big, it will touch the lower cradle, it will completely fill the combustion chamber and, above all, it will be of a red colour and not transparent.

4.8 - CHECKS TO BE CARRIED OUT AFTER FIRST START-UP

CHECKING SEALS

During the initial start-up, check the tightness of the smoke circuit and the connection to the chimney. If there is any noticeable smoke leakage, alert the installer and/or our After-Sales Service. If there is any noticeable aspiration of air through the door seals, tighten the handle with greater force.Make sure the working thermostat is in good

running order Te (32) at full power (chap. 3.12) until it stops the fan.Check for leaks from pipe connections.After the initial start, with the boiler off, open the lower door and inspect the internal walls and insulation of the door: they should be of a light colour, indicative of a proper air adjustment.Otherwise, if the walls are blackened, it means the secondary air is not adjusted properly (par. 4.7 and 4.9).

28


4.9 - WARNINGS HOW TO AVOID CORROSION IN THE WOOD STORAGE COMPARTMENT

The use of wood with a high moisture content (higher than about 25%) and/or loads not proportioned to the system’s heat request (long OFF periods with the wood storage full) can cause considerable condensate formation in the storage compartment’s internal wall.Check the steel walls of the upper wood storage

once a week.They must be covered by a slight layer of dry tar, opaque coloured, with bubbles tending to break and fall off. On the other hand, the tar will have a glossy, runny appearance and liquid will appear if it is removed with a poker: accordingly, it is necessary to use wood that is less damp and/or reduce the amount of loaded wood.If, despite these interventions, the tar does not dry, you must inform the local After-Sales Service.The condensate inside the firewood storage compartment causes the steel sheets to corrode.Corrosion is not covered by the warranty, as it is caused by improper use of the boiler (wet wood, excessive loading, etc.).

CORROSION OF THE FLUE CIRCUIT

Flue gas is rich in water vapour, due to combustion and the use of wood which retains water.If the flue gas comes into contact with relatively cold surfaces (having a temperature below 60 - 70 °C), the water vapour condensates and, combining with other combustion products, originates corrosion of the metallic parts.Check daily whether there are signs of flue gas condensation (black liquid on the floor and behind the boiler). In this case you must use wood with a lower moisture content; check that the recirculation pump is working correctly and the flue gas temperature at partial load, and increase the working temperature. In order to control the room temperature, it is

therefore necessary to install a mixer valve. The corrosion caused by the flue gas condensation is not covered by the warranty, as it is caused by the wood’s moisture content and the way the boiler is used.

WARNINGS DURING USE

Every time the air is adjusted, wait 5-10 minutes before proceeding with the next adjustment. When you have established the best air adjustment, at the end of the day, check the surfaces of the combustion chamber and the door insulation as they should be white.There must be only a few unburnt embers in the ash deposited in the cradle. If there is too much primary air, there will be ember and small pieces of coal in the ashes, the flame will be quick, dry, a cooler colour and will make more noise, with excessive power (chap. 4.7).If the primary air is insufficient, the flame will be slow, small, it will not caress the lower cradle, dragging few ashes and the heat output will be insufficient.If the flame is dark orange, the secondary air is insufficient and the surfaces of the combustion chamber will not be white; if it is small and blue, there is too much secondary air.Always open the loading door and the internal anti-smoke door slowly.If blowbacks occur regardless of this warning, it will be necessary to use larger logs, a bit damper, and make sure that the boiler does not have prolonged downtime (reduce primary air - chap. 4.7), that there are no broken bars or changes to the grates or that there is no foreign matter (nails, metal pieces) blocking the hole in the refractory burner.

4.10 - THERMOSTAT ADJUSTMENT

WOOD BOILERThe boiler adjusting thermostat must be calibrated to the required temperature (the range of adjustment, limited by stops that can not be removed, varies from 75° to 85°C).To adjust the flow temperature of the heating

system a 3 or 4-way mixer valve must be fitted.Failure to install the valve makes the warranty null and void.The safety thermostat pos. 31, manually reset, complies with relevant provisions in force.When commissioning the boiler, make sure that it does not need to be reset.In order to do this, unscrew the plastic protective cap and press the release button. Afterwards put the plastic cap back on.

Should the boiler's safety thermostat triggers frequently pos. 31, reduce the temperature of the working thermostat (pos. 32 on the electrical control panel).If the problem repeats itself, alert the After-Sales Service.

29


4.11 - SUMMER MODE

The use of the boiler in summer only for the production of domestic hot water is not advised, unless you follow these rules meticulously:1) Use very dry wood.2) Load a small amount of wood in the boiler 2 or 3 times a day as needed.

IMPORTANTIt is very wrong to load the boiler completely, providing it with long self-sufficiency (for example 24 hours). This way the boiler (with the fan stopped) would produce much acid condensation corroding the wood storage compartment.

4.12 - TROUBLESHOOTING

WOOD BOILER:

Problem:- The fan does not start.Remedy:- Calibrate the adjustment (pos. 32) by turning the

knob clock-wise until it reaches the end of the ther-mostat limit switch.

- Reset the safety thermostat pos. 31.

Problem:- The fan starts and stops after about 30 min.; by

turning the main switch ON and OFF pos. 11, it will start up again.

Remedy:- Increase the TIMED RELAY trigger time, (this oper-

ation must be carried out by the Technical Assis-tance, i.e. authorised staff, once the panel board has been powered off).

Problem:- When opening the loading door there are blowbacks

and smoke escape.Remedy:- Open slowly.- Use damper wood, make sure that the boiler has not

have prolonged downtime(see chap. 4.9).- Use larger logs.- Consume the previous load of wood before reload-

ing.

Problem:- The boiler does not reach the requested temperature. The flame is small and there is too much air. Inspecting the wood storage, the formation of log

bridges is found.<B>Remedy:- Check the length of the logs (see chap. 4.6).- Check the arrangement of the logs (see chap. 4.6).- Cut the logs in half (see chap. 4.6).- Use smaller blogs (round or square, about 5-7 cm

diameter).- Mix medium-large sized logs (round or square, about

15-20 cm diameter) with small sized logs (see previ-ous point).

Problem:- The boiler does not reach the requested temperature.

The flame is too small.Remedy:- Check the fan.- Check if the doors are properly closed.

If you cannot solve the problem, do no attempt any other interventions and contact an authorised Firex After-Sales Service..

30

Inspections and maintenance

Inspections and maintenance performed professionally and according to a regular schedule as well as the use of original spare parts are of the utmost importance for fault-free operation of the boiler and to guarantee its long life. The appliance must be serviced according to the indications stated herein, and in accordance with local legislation and/or regulations.

Fai lure to perform Inspections and Maintenance can entail material and personal damage.

We therefore recommend stipulating an inspection or maintenance contract.

Inspections help to determine the actual status of the appliance and to compare it with the nominal status. This is done through measuring, controls and observation.

Maintenance is required to eliminate any differences between the actual status and the nominal status. This is normally done by cleaning, setting and replacing individual components subject to wear.

Maintenance intervals and their extent are determined by a specialist based on the status of the appliance ascertained through inspection.

Inspection and maintenance instructions

To assure long-term functioning of your appliance and to avoid altering its approved status, only original Firex spare parts must be used.

Before proceeding with maintenance, always perform the following operations: • Isolate the appliance from the electric mains by means

of an isolated device with a contact opening of at least 3 mm (e.g. safety devices or power switches) and make sure that it cannot be re-connected accidentally.

• Close the supply gas shut-off valve to the back-up boiler, upstream of the boiler itself.

• Close the shut-off valves on the heating flow and return pipes, as well as the cold water inlet valve.

INSPECTIONS ANDMAINTENANCE

5

Door micro-switch adjustment

By-pass seal/cleaning

Primary and secondary air duct cleaning

Fan: general overhaul and inspection of the state of the impeller, cleaning and lubricating the bearings, checking the direction of rotation and that the impeller spins freely

Check the hermetic seal of the doors

Make sure the sealing gaskets are intact

Check the operation of the safety devices

Cleaning smoke ducts

Make sure the refractory stones are intact

Cleaning and re-positioning the fire bars/burner

X

X

X

X

X

X

X

X

X

X

X

Every year

Lubricating/greasing hinges and door opening levers

X

MAINTENANCE OPERATIONS

X

Thorough cleaning of the furnace and smoke ducts, removing any build-up and soot

• Any solid residues that have been removed and any parts that have been removed must be disposed of in accord-ance with legislation in force.

• When the maintenance operations are finished, the initial connections must be set back up.

• You must make sure that the device starts up as required, ensuring that there is no return of the combustion products during operation.

• In case of any irregularities, make sure: - the air intakes are working correctly; - that the chimney draught is correct;

- that the difference in pressure between installation room and outdoor environment is greater than 4 Pa.

• At the end of the check and/or maintenance operations, the professionally qualified technical staff will issue an intervention report to the user, indicating:

- any parts that have been replaced or installed; - any remarks, strong advice and requirements.• The user must keep the report safe together with the doc-

uments supplied with the appliance so that it is available for future consultation.

Draught calibration adjuster

31

Inspections and maintenance

Boiler body maintenance

Danger!Before performing any maintenance, make sure the boiler and its components have cooled down.

Warnings - Never drain water from the system, even partially, unless

absolutely necessary.- Periodically check the proper operation and integrity of

the flue gas exhaust pipe and/or device.- If work or maintenance is performed on the structures

near the flue gas pipes and/or flue gas exhaust devices and their accessories, switch the appliance off and, when the work is over, check their efficiency.

- Do not clean the boiler and/or its parts with easily flammable substances (e.g. petrol, alcohol, etc.).

- Do not leave flammable substances in the room where the boiler is installed.

- Do not clean the boiler room while the boiler is running.- At the end of each heating period, inspect the boiler to

keep the system in perfect efficiency. Thorough maintenance always enhances energy saving

and safety.

IMPORTANTUse brushes and a vacuum cleaner to clean the heat stove; if rags are used, make sure they are all recovered.Keep screws and nuts oiled and protect them with grease.

CLEANING AND ROUTINE MAINTENANCE OF THE WOOD-FUELLED BOILER

Daily- Remove the ashes from the lower cradle.- Shake down, with the scraper supplied with the boiler, the

embers so that the ashes, accumulated in the fire bed will fall down through the slots in the grate. This operation will help to avoid the grate from becoming obstructed and the subsequent bad operation of the boiler. This operation has to be done when the flame dies down, before loading wood.

Every week- Remove carefully all the residues of combustion

accumulated in the firewood storage compartment.- Use the supplied brush to clean the triangular ducts in the

furnace.- Remove the ashes contained in the smoke chamber from

the side doors using a scraper.- Make sure that the slots in the grate are not obstructed: if

they are, clear them up using the poker.- If the boiler continues to operate badly, even after having

cleaned it as described above, the cause can be attributed to bad distribution of the secondary air.

In this case: 1) check the adjustment of the air setting, according to

the instructions given in the paragraph “Combustion air adjustment”;

2) make sure that the two secondary air supply holes that come through the grate are not obstructed: if they are, use a soft brush to clean out each duct.

Every monthCheck that the bypass is working as indicated in paragraph 4.5 and that when the loading door is closed, the bypass is hermetically sealed.

UNSCHEDULED MAINTENANCE OF WOOD-FUELLED BOILER

At the end of each heating season, perform a general cleaning of the boiler by removing all the ashes from the firewood storage compartment. During the summer season, close the boiler doors.

Cleaning fan

ATTENTION: First of all, cut off the power.Open the rear fan and clean any build-up off of the blades.Normally with the use of compressed air or a brush it is possible to clean it properly.

If the incrustations are more resistant, due to the formation of condensate or tar dripping, clean very carefully in order not to bend or deform the blades. This could make the fan noisy during operation and could reduce the fan’s performance.

Cleaning primary and secondary air distribution.Take out the central wall (fig. 30) where the air adjustment valves are installed and thoroughly clean the tar residues, dust and shards of wood out of the inside gap, that have gone through the primary air duct holes.Using a soft brush, clean out the secondary air ducts.

Cleaning the fire grate and bars.

The refractory steel grate and fire bars are subject to wear: it is therefore advisable to carry out an annual inspection to prevent faulty boiler operation.THIS OPERATION MUST BE CARRIED OUT BY A PROFESSIONALLY QUALIFIED TECHNICIAN.

1 Main stone2 Stainless steel fire bars3 Stainless steel central grate4 Side fire bar insulation

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1

3

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Autom

atic Heating P

tyLtd

AB

N 90 446 545 923

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1800 337 959 +61 3 9310 [email protected]

P.O. Box 35 Epping VIC 3076 Australiawww.automaticheating.com.au

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